Heat and flame shield

ABSTRACT

A heat and fire resistant planar unitary shield formed of heat and flame resistant fibers and voluminous bulking fibers. The shield material has a heat and flame resistant zone with a majority of the heat and flame resistant fibers, and a voluminous bulking zone with a majority of the voluminous bulking fibers. The fibers are distributed through the shield material in an manner that the heat and flame resistant fibers collect closest to the outer surface of the shield with the heat and flame resistant zone, and the voluminous bulking fibers collect closest to the outer surface of the shield material with the voluminous bulking zone.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No. 11/123,337filed on May 6, 2005, now U.S. Pat. No. 7,229,938 which is acontinuation-in-part of prior U.S. application Ser. No. 10/841,148 filedMay 7, 2004, now U.S. Pat. No. 7,153,794 the contents of all of whichare incorporated by reference herein in their entirety.

BACKGROUND

The present invention generally relates to materials for use inshielding from heat and/or flame, and in particular, heat and/or flameshielding material that can be used in applications such as hood linersfor automobiles, engine compartment liners, bedding construction,upholstery, wall padding, and the like.

Numerous industries require materials which not only deliver heat andflame resistant properties, but can also provide volume, opacity,moldability, and other properties in a cost effective single substrate.Often times these barrier properties are best accomplished by usingspecialty materials which generate a high level of performance, but alsointroduce significant cost to the substrate. Especially in a voluminoussubstrate (high z direction thickness) even the introduction of a smallpercent of these materials into the shield material can introduce asignificant level of cost to the overall substrate. For this reasoncomposites having specialty surface layers are often used to providethese barrier properties. An example of a composite having specialtysurface layers would be a skin laminated to a voluminous lower costmaterial. While this method effectively reduces the cost of the highcost raw material, there are disadvantages to this method such asadditional processing steps and the potential delamination of the skinlayer.

The present invention provides an alternative to the prior art by usinga unitary heat shield material with different zones to provide thevarious desired properties of the material

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood with regard to the followingdescription, appended claims, and accompanying drawings where:

FIG. 1 shows an enlarged cross-section of one embodiment of the presentinvention;

FIG. 2 shows an enlarged cross-sectional view of another embodiment ofthe present invention;

FIG. 3 shows a diagram of a machine for performing a process for formingthe planar heat and flame resistant shield material of the presentinvention;

FIG. 4 shows a magnified cross sectional view of a shield materialaccording to the embodiment in FIG. 1;

FIG. 5 shows a perspective view of a bed utilizing the shield materialof the present invention; and,

FIG. 6 shows an enlarged partial view of the walls from the bed in FIG.5, and the shield material incorporated therein.

DETAILED DESCRIPTION

Referring now to the figures, and in particular to FIG. 1, there isshown an enlarged cross-sectional view of an embodiment of the presentinvention, illustrated as a planar heat and flame shield material 100.The shield material 100 may be used in its existing sheet form as aprotective blanket or shield in operations such as welding, hightemperature manufacturing, or the like. The shield material 100 may alsobe formed into parts such as automotive hood liners, engine compartmentcovers, and the like. Additionally, the shield material 100 can beincorporated with other materials, and/or into a structure to providethe materials and structures with additional heat and flame resistance.For example, the shield material 100 can be incorporated into the outermaterial of a bed, upholstery, wall padding, and other structures toprovide additional flame and heat resistance to those structures.Because of the bulk associated with the shield material 100,incorporating the shield material 100 into such structures may alsoprovide a cost benefit by replacing any bulking material in thestructures.

As illustrated, the planar shield material 100 generally contains heatand flame resistant fibers 101 and bulking fibers 102. The heat andflame resistant fibers 101 and the bulking fibers 102 are staple fibersthat are combined to form the shield material 100. As used herein, heatand flame resistant fibers shall mean fibers having an Limiting OxygenIndex (LOI) value of 20.95 or greater, as determined by ISO 4589-1.Types of heat and flame resistant fibers include, but are not limitedto, fire suppressant fibers and combustion resistant fibers. Firesuppressant fibers are fibers that meet the LOI by consuming in a mannerthat tends to suppress the heat source. In one method of suppressing afire, the fire suppressant fiber emits a gaseous product duringconsumption, such as a halogentated gas. Examples of fiber suppressantfibers includes modacrylic, PVC, fibers with a halogenated topicaltreatment, and the like. Combustion resistant fibers are fibers thatmeet the LOI by resisting consumption when exposed to heat. Examples ofcombustion resistant fibers include silica impregnated rayon such asrayon sold under the mark VISIL®, partially oxidized polyacrylonitrile,polyaramid, para-aramid, carbon, meta-aramid, melamine and the like.Bulking fibers are fibers that provide volume to the heat shieldmaterial. Examples of bulking fibers would include fibers with highdenier per filament (one denier per filament or larger), high crimpfibers, hollow-fill fibers, and the like.

In one embodiment, the heat and flame resistant fibers 101 and thebulking fibers 102 are air-laid with a binder fiber 105. Binder fibersare fibers that form some type of adhesion or bond with the otherfibers. Binder fibers can include fibers that are heat activated. Anadditional benefit of using a binder fiber 105 in the shield material100 that is heat activated, is that the shield material 100 can besubsequently molded to part shapes for use in automotive hood liners,engine compartment covers, etc. Examples of heat activated binder fibersare fibers that can melt at lower temperatures, such as low melt fibers,core and sheath fibers with a lower sheath melting temperature, and thelike. In one embodiment, the binder fibers are a polyester core andsheath fiber with a low melt temperature sheath.

Still referring to FIG. 1, the heat and flame resistant fibers 101 areconcentrated in a heat and flame resistant zone 110 of the planar shieldmaterial 100, and the bulking fibers 102 are concentrated in avoluminous bulking zone 120 of the planar shield material 100. The heatand flame resistant zone 110 provides the shield material 100 with theprimary heat and flame resistant attributes. The voluminous bulking zone120 provides the shield material 100 with the desired z-directionthickness which extends horizontally from the planar dimension of theshield material 100. In the embodiment illustrated in FIG. 1, the heatand flame resistant zone 110 is smaller in the z-direction than thevoluminous bulking zone 120.

Referring still to FIG. 1, the heat and flame resistant zone 110 has anouter boundary 111 located at the outer surface of the shield material100, and an inner boundary 112 located adjacent to the voluminousbulking zone 120. The voluminous bulking zone 120 has an outer boundary121 located at the outer surface of the shield material 100 and an innerboundary 122 located adjacent to the heat and flame resistant zone 110.The shield material 100 is a unitary material, and the boundaries of thetwo zones do not represent the delineation of layers, but areas withinthe unitary material. Because the shield material 100 is a unitarymaterial, and the heat and flame resistant zone 110 and the voluminousbulking zone 120 are not discrete separate layers joined together,various individual fibers will occur in both the heat and flameresistant zone 110 and the voluminous bulking zone 120. Although FIG. 1illustrates the heat and flame resistant zone 110 being a smallerthickness than the voluminous bulking zone 120, the relative thicknessof the two zones can have a substantially different than as shown.

Referring still to FIG. 1, the heat and flame resistant zone 110contains both the heat and flame resistant fibers 101 and the bulkingfibers 102. However, the heat and flame resistant zone 110 primarilycontains the heat and flame resistant fibers 101. Additionally, thedistribution of the fibers in the heat and flame resistant zone 110 issuch that the concentration of the heat and flame resistant fibers 101is greater at the outer boundary 111 of the heat and flame resistantzone 110 than the inner boundary 112 of that zone. Also, as illustrated,it is preferred that the concentration of the heat and flame resistantfibers 101 decreases in a gradient along the z-axis from the outerboundary 111 of the heat and flame resistant zone 110 to the innerboundary 112 of that zone.

Still referring to FIG. 1, the voluminous bulking zone 120 contains boththe heat and flame resistant fibers 101 and the bulking fibers 102.However, the voluminous bulking zone 120 primarily contains the bulkingfibers 102. Additionally, the distribution of the fibers in thevoluminous bulking zone 120 is such that the concentration of thebulking fibers 102 is greater at the outer boundary 121 of thevoluminous bulking zone 120 than the inner boundary 122 of that zone.Also, as illustrated, it is preferred that the concentration of thebulking fibers 102 decreases in a gradient along the z-axis from theouter boundary 121 of the voluminous bulking zone 120 to the innerboundary 122 of that zone.

Referring now to FIG. 2, there is shown an enlarged cross-sectional viewof another embodiment of the present invention, illustrated as a heatand flame shield material 200. As illustrated, the shield material 200generally contains heat and flame resistant fibers 201 and bulkingfibers 202. The heat and flame resistant fibers 201 and the bulkingfibers 202 are staple fibers that are combined to form the shieldmaterial 200. In one embodiment, the heat and flame resistant fibers 201and the bulking fibers 202 are air-laid with a binder fiber 205. Whenthe binder fiber 205 is a heat activated binder fiber, the combinationof fibers is heated to activate the binder fiber 205 for bondingtogether the fibers of the shield material 200. An additional benefit ofusing a heat activated binder fiber as the binder fiber 205 in theshield material 200 is that the shield material 200 can be subsequentlymolded to part shapes for use in automotive hood liners, enginecompartment covers, etc.

Still referring to FIG. 2, the heat and flame resistant fibers 201 areconcentrated in a heat and flame resistant zone 210 of the shieldmaterial 200, and the bulking fibers 202 are concentrated in avoluminous bulking zone 220 of the shield material 200. The heat andflame resistant zone 210 provides the shield material 200 with theprimary heat and flame resistant attributes of the shield material 200.The voluminous bulking zone 220 provides the shield material 200 withthe desired z-direction thickness. In the embodiment illustrated in FIG.2, the heat and flame resistant zone 210 is smaller in the z-directionthan the voluminous bulking zone 220.

Referring still to FIG. 2, the heat and flame resistant zone 210 has anouter boundary 211 located at the outer surface of the shield material200, and an inner boundary 212 located adjacent to the voluminousbulking zone 220. The voluminous bulking zone 220 has an outer boundary221 located at the outer surface of the shield material 200 and an innerboundary 222 located adjacent to the heat and flame resistant zone 210.The shield material 200 is a unitary material, and the boundaries of thetwo zones do not represent the delineation of layers, but areas withinthe unitary material. Because the shield material 200 is a unitarymaterial, and the heat and flame resistant zone 210 and the voluminousbulking zone 220 are not discrete separate layers joined together,various individual fibers will occur in both the heat and flameresistant zone 210 and the voluminous bulking zone 220. Although FIG. 2illustrates the heat and flame resistant zone 210 being a smallerthickness than the voluminous bulking zone 220, the relative thicknessof the two zones can have a substantially different than as shown.

Still referring to FIG. 2, the heat and flame resistant zone 210contains both the heat and flame resistant fibers 201 and the bulkingfibers 202. However, the heat and flame resistant zone 210 primarilycontains the heat and flame resistant fibers 201. Additionally, thedistribution of the fibers in the heat and flame resistant zone 210 issuch that the concentration of the heat and flame resistant fibers 201is greater at the outer boundary 211 of the heat and flame resistantzone 210 than the inner boundary 212 of that zone. Also, as illustrated,it is preferred that the concentration of the heat and flame resistantfibers 201 decreases in a gradient along the z-axis from the outerboundary 211 of the heat and flame resistant zone 210 to the innerboundary 212 of that zone.

Referring still to FIG. 2, the bulking fibers 202 of the shield material200 comprise first bulking fibers 203 and second bulking fibers 204. Inone embodiment, the first bulking fibers have a higher denier perfilament, and/or mass per fiber, than the heat and flame resistantfibers 201, and the second bulking fibers 204 have a higher denier perfilament, and/or mass per fiber, than the first bulking fiber 203 andthe heat and flame resistant fibers 201. Also, the voluminous bulkingzone 220 is divided into a first bulking zone 230 and a second bulkingzone 240. The first bulking zone 230 has an outer boundary 231 locatedadjacent to the heat and flame resistant zone 210 and inner boundary 232located adjacent to the second bulking zone 240. The second bulking zone240 has an outer boundary 241 located adjacent to the outer surface ofthe shield material 200 and an inner boundary 242 located adjacent tothe first bulking zone 230. As previously stated, the shield material200 is a unitary material, and as such, the boundaries of the twobulking zones do not represent the delineation of layers, but areas within the unitary material. Because the shield material 200 is a unitarymaterial, and the first bulking zone 230 and the second bulking zone 240are not discrete separate layers joined together, various individualbulking fibers will occur in both the first bulking zone and the secondbulking zone 240. Although FIG. 2 illustrates the heat and flameresistant zone 210 being a smaller thickness than the voluminous bulkingzone 220, the relative thickness of the two zones can have asubstantially different than as shown.

Still referring to FIG. 2, the first bulking zone 230 contains both thefirst bulking fibers 203 and the second bulking fibers 204. However, thefirst bulking zone 230 will contain more of the first bulking fibers 203than the second bulking fibers 204. The distribution of the fibers inthe first bulking zone 230 is such that the concentration of the firstbulking fibers 203 increases in a gradient along the z direction fromthe outer boundary 231 of the first bulking zone 230 to a first bulkingfiber concentration plane 235 located between the inner boundary 232 andthe outer boundary of the first bulking zone. Also, as illustrated, itis preferred that the concentration of the first bulking fibers 203decreases in a gradient along the z-axis from the first bulking fiberconcentration plane 235 to the inner boundary 232 of that zone.

Referring still to FIG. 2, the second bulking zone 240 contains both thefirst bulking fibers 203 and the second bulking fibers 204. However, thesecond bulking zone 240 will contain more of the second bulking fibers204 than the first bulking fibers 203. The distribution of the fibers inthe second bulking zone 230 is such that the concentration of the secondbulking fibers 204 is greater at the outer boundary 241 of the secondbulking zone 240 than the inner boundary 242 of that zone. Also, asillustrated, it is preferred that the concentration of the secondbulking fibers 204 decreases in a gradient along the z-axis from theouter boundary 241 of the second bulking zone 240 to the inner boundary242 of that zone.

Still referring to FIG. 2, the first bulking zone 230 will also containheat and flame resistant fibers 201. However, the first bulking zone 230will contain more of the first bulking fibers 203 than the heat andflame resistant fibers 201. The heat and flame resistant zone 210 canhave some amount of the second bulking fiber 204; however, the amount ofsecond bulking fiber 204 in the heat and flame resistant zone 210 issignificantly lower than the first bulking fibers 203. The secondbulking zone 240 can also have some amount of the heat and flameresistant fibers 201; however, the amount of the heat and flameresistant fibers 201 in the second bulking zone 240, if any, issignificantly lower than the first bulking fibers 203. An advantage ofusing the two distinct bulking fibers 203/204 (FIG. 2) over using asingle bulking fiber 102 (FIG. 1), is that for the same respectiveweights of heat and flame resistant fibers 101/201 and voluminousbulking fibers 102/202, a shield material 200 having two types ofbulking fibers 203 and 204 will have fewer heat and flame resistantfibers 201 located in the voluminous bulking zone 120/220 than a shieldmaterial 100 having only one type of bulking fiber 102.

Referring now to FIGS. 1 and 2, it is contemplated that the shieldmaterial 100/200 can include additional fibers that create additionalzones extending outward from the bulking zone 120/220. In suchembodiments, the outer boundary 121/221/241 of the bulking zone 120/220will not be adjacent to the exterior of the shield material 100/200, butwill be disposed in the interior of the shield material 100/200. Theadditional zones will also have an area of transition in theconcentration of the bulking fibers 102/204 to the additional fibers,similar to the transition of the first bulking fibers 203 to the secondbulking fibers 204 in the shield material 200. Multiple additional zonescan be created with multiple additional fibers, resulting in manyadditional zones. In the outer most additional zone, the fibers creatingthat outer most additional zone will be concentrated at the exterior ofthe shield material 100/200 similar to the bulking fibers 102 and 204 asshown in FIGS. 1 and 2.

Referring now to FIG. 3, there is shown a diagram of a particular pieceof equipment 300 for the process to form the planar unitary heat andflame shield from FIGS. 1 and 2. A commercially available piece ofequipment that has been found satisfactory in this process to form theclaimed invention is the “K-12 HIGH-LOFT RANDOM CARD” by Fehrer AG, inLinz, Austria. The heat and flame resistant fibers 101/201 and thevoluminous bulking fibers 102/202 are opened and blended in theappropriate proportions and enter an air chamber 310. In an embodimentusing the binder fibers 105/205, the binder fibers 105/205 are alsoopened and blended with the heat and flame resistant fibers 101/201 andthe bulking fibers 102/202 prior to introduction into the air chamber310. In an embodiment where the voluminous bulking fibers 202 containmultiple types of bulking fibers 203/204, those multiple types ofbulking fibers 203/204 are also opened and blended in the appropriateportions with the other fibers before introduction into the air chamber310. The air chamber 310 suspends the blended fibers in air, and areexpelled for delivery to an air lay machine that uses a cylinder 320.The cylinder 320 rotates and slings the blended fibers towards acollection belt 330. The spinning rotation of the cylinder 320 slingsthe heavier fibers a further distance along the collection belt 330 thanit slings the lighter fibers. As a result, the mat of fibers collectedon the collection belt 330 will have a greater concentration of thelighter fibers adjacent to the collection belt 330, and a greaterconcentration of the heavier fibers further away from the collectionbelt 330. In general, the larger the difference in denier between thefibers, the greater the gradient will be in the distribution of thefibers.

In the embodiment of the shield 100 illustrated in FIG. 1, the heat andflame resistant fibers 101 are lighter than the voluminous bulkingfibers 102. Therefore, in the process illustrated in FIG. 3, the heatand flame resistant fibers 101 collect in greater concentration near thecollection belt 330, and the voluminous bulking fibers 102 collect ingreater concentration away from the collection belt 330. It is thisdistribution by the equipment 300 that creates the heat and flameresistant zone 110 and the voluminous bulking zone 120 of the planarunitary shield material 100.

In the embodiment of the shield 200 illustrated in FIG. 2, the heat andflame resistant fibers 201 are lighter than the voluminous bulkingfibers 202. Therefore, in the process illustrated in FIG. 3, the heatand flame resistant fibers 201 collect in greater concentration near thecollection belt 330, and the voluminous bulking fibers 202 collect ingreater concentration away from the collection belt 330. It is thisdistribution by the equipment 300 that creates the heat and flameresistant zone 210 and the voluminous bulking zone 220 of the planarunitary shield material 200. Additionally, the first bulking fibers 203of the voluminous bulking fibers 220 are lighter than the second bulkingfibers 204. Therefore, in the process illustrated in FIG. 3, the firstbulking fibers 203 are collected in greater concentration nearer thecollection belt 330 than the second bulking fibers 204. It is thisdistribution that creates the first bulking zone 230 and the secondbulking zone 240 of the voluminous bulking zone 220 of the planarunitary shield material 200.

In formation of the shield material 100/200, the combined percentage ofheat and flame resistant fibers can range from about 10% by totalweight, to about 90% by total weight. The combined percentage of bulkingfibers in the shield material 100/200 can range from about 80% by totalweight, to about 5% by total weight. An optimum amount of binder fibersin the shield material 100/200 can range from about 10% by total weightto about 40% by total weight. It has been found that a high loft shieldmaterial provides a desirable product for quilting with other materialsto use in applications such as mattress borders and panels. Thecombination of bulking fibers with the heat and flame resistant fibersin the present process reduces costs by reducing steps and gives betterperformance than combining two separate layers of the materials forcriteria such as de-lamination. Additionally, the performance of theshield material appears to have better flame resistance for the samecost, and a lower cost for similar performance.

In a first example of the present invention, planar unitary heat andflame resistant shield material was formed from a blend of four fibersincluding:

-   -   1) 4% by weight of a heat and flame resistant fiber being 2 dpf        partially oxidized polyacrylonitrile    -   2) 25% by weight of a first bulking fiber being 6 dpf polyester    -   3) 41% by weight of a second bulking fiber being 15 dpf        polyester, and    -   4) 30% by weight of a low melt binder fiber being 4 dpf core        sheath polyester with a lower melting temperature sheath.        The fibers were opened, blended and formed into a shield        material using a “K-12 HIGH-LOFT RANDOM CARD” by Fehrer AG. The        shield had a weight per square yard of about 16-32 ounces and a        thickness in the range of about 12-37 mm. In the resulting        shield material, the heat and flame resistant fibers in the heat        and flame resistant zone comprised at least 70% of the total        fibers in that zone, and the heat and flame resistant fibers in        the voluminous bulking zone were less than about 2% of the total        fibers in that zone.

In a second example of the present invention, planar unitary heat andflame resistant shield material was formed from a blend of four fibersincluding:

-   -   1) 40% by weight of a heat and flame resistant fiber being about        3.2 dpf Visil®    -   2) 20% by weight of about 2 dpf modacrylic(Kanecaron™)    -   3) 20% by weight of a bulking fiber being 15 dpf polyester, and    -   4) 20% by weight of a low melt binder fiber being 4 dpf core        sheath polyester with a lower melting temperature sheath.        The fibers were opened, blended and formed into a shield        material using the “K-12 HIGH-LOFT RANDOM CARD” by Fehrer AG.        The shield had a weight per square yard of about 8 ounces and a        thickness in the range of about 25 mm. In the resulting shield        material, the heat and flame resistant fibers in the heat and        flame resistant zone comprised at least 60% of the total fibers        in that zone, and the heat and flame resistant fibers in the        voluminous bulking zone were less than about 40% of the total        fibers in that zone. In an alternate version of the second        example, the low melt binder fiber was a 10 dpf core sheath        polyester with a lower melting temperature sheath.

In a third example of the present invention, planar unitary heat andflame resistant shield material was formed from a blend of four fibersincluding:

-   -   1) 30% by weight of a heat and flame resistant fiber being about        3.2 dpf Visil®    -   2) 30% by weight of about 2 dpf modacrylic (Kanecaron™)    -   3) 20% by weight of a bulking fiber being 15 dpf polyester, and    -   4) 20% by weight of a low melt binder fiber being 4 dpf core        sheath polyester with a lower melting temperature sheath.        The fibers were opened, blended and formed into a shield        material using the “K-12 HIGH-LOFT RANDOM CARD” by Fehrer AG.        The shield had a weight per square yard of about 8 ounces and a        thickness in the range of about 25 mm. In the resulting shield        material, the heat and flame resistant fibers in the heat and        flame resistant zone comprised at least 60% of the total fibers        in that zone, and the heat and flame resistant fibers in the        voluminous bulking zone were less than about 40% of the total        fibers in that zone.

In a fourth example of the present invention, planar unitary heat andflame resistant shield material was formed from a blend of four fibersincluding:

-   -   1) 40% by weight of a heat and flame resistant fiber being about        3.2 dpf Visil®    -   2) 40% by weight of about 2 dpf modacrylic (Kanecaron™)    -   3) 15% by weight of a bulking fiber being 15 dpf polyester, and    -   4) 5% by weight of a low melt binder fiber being 4 dpf core        sheath polyester with a lower melting temperature sheath.        The fibers were opened, blended and formed into a shield        material using the “K-12 HIGH-LOFT RANDOM CARD” by Fehrer AG.        The shield had a weight per square yard of about 10 ounces and a        thickness in the range of about 25 mm. In the resulting shield        material, the heat and flame resistant fibers in the heat and        flame resistant zone comprised at least 60% of the total fibers        in that zone, and the heat and flame resistant fibers in the        voluminous bulking zone were less than about 40% of the total        fibers in that zone.

In a fifth example of the present invention, planar unitary heat andflame resistant shield material was formed from a blend of four fibersincluding:

-   -   1) 50% by weight of a heat and flame resistant fiber being 2 dpf        panox    -   2) 30% by weight of a bulking fiber being 15 dpf polyester, and    -   4) 20% by weight of a low melt binder fiber being 4 dpf core        sheath polyester with a lower melting temperature sheath.        The fibers were opened, blended and formed into a shield        material using the “K-12 HIGH-LOFT RANDOM CARD” by Fehrer AG.        The shield had a weight per square yard of about 6 ounces and a        thickness in the range of about 25 mm. In the resulting shield        material, the heat and flame resistant fibers in the heat and        flame resistant zone comprised at least 60% of the total fibers        in that zone, and the heat and flame resistant fibers in the        voluminous bulking zone were less than about 40% of the total        fibers in that zone.

Referring now to FIG. 4, there is shown an enlarged cross sectional viewof an embodiment of the shield material 100 from FIG. 1 formed accordingto the method disclosed with reference to FIG. 3. FIG. 4 illustrates theheat and flame resistant zone above the bulking zone. As can be seen,the fibers have an orientation with the mode of the angle being atapproximately 30 degrees, which is most pronounced in the bulking zone.The angle of the fibers are a result of the manufacturing process, andgive the shield material a stiffness and resiliency. The mode of theangle for the fibers can vary from about 5 degrees to about 80 degreestowards the horizontal z-direction from the planar dimensions of theshield material 100.

Referring now to FIG. 5, there is shown a mattress incorporating theshield material 100/200. The mattress 500 includes a first side 511, anopposing second side 512, and at least one of side walls 521, 522, 523,and 524 connecting the first side 511 and the second side 512.Illustrated in FIG. 6 is a partial cutaway view of a wall 600 used forthe sides 511, 512, or walls 521, 522, 523, and 524 of the mattress 500in FIG. 5. As illustrated, the wall 600 includes an exterior tickingmaterial 610, a shield material 620, a support material 630, and abacking material 640. The shield material 100/200 described above inreference to FIGS. 1-4, can be used as the shield material 620 in thewall 600 and is preferably oriented with the heat and flame resistantzone nearest to the exterior ticking material 610. The support material630 is a resilient material such as foam, nonwoven, or the like. Thebacking material 640 is a flexible material such as a woven, knitted, ornonwoven textile.

Although the present invention has been described in considerable detailwith reference to certain preferred versions thereof, other versions arepossible. For example, an additional layer of material such as anonwoven can be added to the outside surface or the inside surface ofthe present invention for additional purposes. Therefore, the spirit andscope of the appended claims should not be limited to the description ofthe preferred versions contained herein.

1. A method of forming a shield material comprising the steps ofblending a plurality of heat and flame resistant fibers having a firstdenier with a plurality of bulking fibers having a second denier beinggreater than the first denier of the heat and flame resistant fibers anda plurality of binder fibers, and projecting the blended heat and flameresistant fibers, binder fibers, and the bulking fibers along a movingbelt such that a unitary nonwoven material is formed on the belt with aheat and flame resistance zone and a bulking zone, whereby the heat andflame resistance zone includes a greater percentage of the heat andflame resistant fibers than the bulking fibers and the bulking zoneincludes a greater percentage of the bulking fibers than the heat andflame resistant fibers.
 2. The method according to claim 1, wherein thestep of blending fibers includes the bulking fibers comprising a firstbulking fiber and a second bulking fiber, the second bulking fiberhaving a greater denier than the first bulking fiber.